ARCADIS Chile.

Mine Waste Management
Draft-Apr 11th 2013
1
ARCADIS is an international company providing
consultancy, engineering and management services in
infrastructure, environment, water and buildings, to
enhance mobility, sustainability and quality of life.
ARCADIS develops, designs, implements, maintains
and operates projects for companies and
governments.
More than
22,000
employees
Gross Revenue
€ 2.5 billion
Over
300 offices in
16 countries
Top 3
Global environmental
market
Top 5
In Europe, Brazil
and Chile
Top 10
Global Management
and engineering consultancies
Where is ARCADIS?
A global network based on strong local positions
Edmonton
Calgary
Korea
Toronto
Kazakhstan
Japan
Morocco
Tunisia
Shanghai
Bahrein
Saudi Arabia
Oman
Mexico
Venezuela
Colombia
São Luis
Somalia
Kenya
Singapore
Tailand
Tanzania
Manaus
Peru
Vientiane
Ethiopia
Congo
Costa Rica
Hong Kong
Taiwan
India
Brasília
Malaysia
Belo Horizonte
Mozambique
Vitória
Rio de Janeiro
São Paulo
Santiago
South Africa
Australia
Argentina
New Zealand
=0
Health & Safety Vision
As a socially responsible company, and through
alignment of H&S with our other core values of
Integrity, Entrepreneurship and Agility, ARCADIS is
committed to being one of the safest and most
healthful companies in our industry. Our
commitment to prevent injuries and illnesses
benefits our employees, clients, partners and all
other stakeholders as we strive for zero incidents in
everything we do.
We value health and
safety as much as our
other core values and
make it an integral part
of the solutions we
provide to our clients.
more than
700
Employees in
Chile & Peru
Member of Program
World Class Route
BHP Escondida
5
Mining Services
ARCADIS provides comprehensive mining
services, from exploration and mine planning to
process design and operation to closure. We offer
an in depth understanding of the mining industry
with:
6
•
Sustainable development practices built into our
mining services to improve your triple bottom line financial success, environmental protection, and
corporate social responsibility.
•
Proven innovative mining technologies
minimize costs and maximize profits.
•
Cost-effective solutions focused on reducing risk
and improving our client’s mining results.
that
What do we do?
Project Lifetime
Strategic
Analysis
Design
(Brown or green field)
• Site evaluation and
selection studies
• Scoping to detailed
engineering studies
• Strategic risk
analysis and follow
up
• Facilities design
• Economic analysis
• Environmental
studies
• Sustainability
analysis
• Process design
• Trade off studies
• Mine Life cycle
planning
• Project planning &
scheduling
• Environmental
baselines studies
• Cost estimating
• Environmental and
socio economic
impact assessment
• Permitting and
regulatory
compliance
• Due diligence
7
• Geological,
geotechnical
geomechanical,
hydrology,
hydrogeology
rheological,
hydraulics and
geochemical studies
• Metallurgical
studies
Construction
• Construction
supervision and
Inspections
• QA/QC
• Project
Management (PM)
• Construction
Management (CM)
• Engineering,
Construction,
Procurement &
Management
(EPCM)
• Procurement
• Bidding process
support
• Commissioning
and start-up
Operation
Closure &
Remediation
• Operation planning
• Mine Closure planning
• Optimization
• Engineering for mine
closure
• Auditing
• Reprocessing
• Regulatory
compliance
• Operation and
maintenance
manuals
• Training courses for
plant operators
• Instrumentation &
monitoring
• Ore processing
operation/
optimization
• Economical
assessment and
guarantees
• Post closure analysis
• Monitoring & follow up
• Natural resource
damage assessments
• Mine waste treatment
technology
Water
Management
• Water and solution
balance modeling
• Water recovery
improvement
• Strategic water
management and
design
• ARD Management
• Effluent treatment
plants design
• Solutions processing
• Water efficiency
• Water treatment,
storage and
conveyance
• Water diversion
works
Mine Waste
Management
Package
ARCADIS Chile offers an in depth understanding
and an integrated vision of the management of
mine wastes:
8
•
Solutions for all the life cycle of mine
projects, from strategic analysis and
environmental studies to mine closure
•
Effluent treatment, tailings storage facilities,
waste rock deposits and leaching tails
•
Water management
•
Cost-efficient and sustainable solutions
General
Services
in MWM
9
• Conceptual and scoping studies
• Environmental and socio
economic impact assessment
• Permitting and regulatory
compliance
• Prefeasibility and feasibility
studies
• Detailed engineering
• Water management
• Bankability studies
• Risk analysis
•
•
•
•
•
•
Mine closure design
Cost engineering
Project planning and scheduling
Project Management
EPCM/PM
Construction QA/QC services
and Inspections
• Commissioning and start-up
Specific
Services
in MWM
10
Effluent
treatment
Waste rock
dump
Tailings storage
facilities
Leaching
tails
• Process modelling for effluent recycle/reuse/minimization
Effluent
Treatment
services
• Conceptual studies for water management
• Conceptual studies for effluent treatment
• Effluent treatment facility design & construction
 EPC, EPM, EPCM, BOT
• Development of new treatment technologies
• Laboratory & pilot testing (design-construction-operation)
• Effluent treatment standarised solutions for:
 Concentrate filtration
 Smelter facilities
• Training & Operation Manuals
• Commissioning and start up
• Technical Expert Review
11
• Design of Tailings storage facilities (TSF)
• Site selection
Tailings
storage
facilities
services
• Tailing distribution systems design
• Tailings transport
• Tailings reprocessing
• Operation advisory
• Tailings dam construction
• Water balance
• Water recovery from tailings
• Optimization of tailings facilities, water supply and
related infrastructure
• Thickened & Paste Tailings
• Filtered /dry stacked Tailings
• Pilot Plant (design-construction-operation)
• Operation and maintenance manuals
• Training courses for plant operators
• Instrumentation and monitoring
• Basic studies: hydrogeology, geology, geotechnics,
hydrology, rheology, geochemistry and hydraulics
• Water management
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• Site selection
Waste rock
dump
services
• Geotechnical and geological studies
• Large scale laboratory testing at high confining
pressures
• Materials characterisation
• Basal drainage design
• Waste rock dump design
• Detailed waste landform design
• Stability analysis (2D-3D), static and dynamic
• Leaching operations design for low grade dumped ore
• Water diversion and collection systems design
• Seepage control facilities design
• Foundation treatment (weak soils, permafrost)
• Geotechnical instrumentation and monitoring
• Acid rock drainage modeling and management
• Recommendations for construction and operation
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stages
• Site selection
• Geotechnical and geological studies
Leaching
tails
services
• Geotechnical and hydrodynamic characterisation
of ores and leached materials
• Tails dump leach design and stability analysis
• Liner system design
• Solution collection ponds and piping design
• Secondary leaching process design
• Solutions processing
• Metallurgical performance assessment
• Integrated solution circuit analysis and design
• Granular materials acceptance criteria, foundations
inspection, on-site laboratory testing
• Recommendations for construction and operational
stages
• Tails dump instrumentation and monitoring
14
MWM experience:
Effluent Treatment
15
Mining Effluent Treatment Facilities designed
by ARCADIS
N°
1
Project
Punta Chungo Effluent Treatment
Plant
Minera Los Pelambres
Effluent
Scope & size
Objetive
From -> To
Copper and Molybdenum
concentrate filtrated water
Design & Construction
Start up
Operation
Flow: 20 L/s
Mo d : 2-10  0,01 mg/L
Mo t : 2,0  0,01
As : 1
 0,1
 1,0
S2- : 70
Cu : 2
 0,2
Cd : 0,05  0,01
2
Puerto Patache Effluent Treatment
Plant
Collahuasi
Copper and Molybdenum
concentrate filtrated water
Design &Construction
Start up
Operation
Flow: 30 L/s
3
Effluents Treatment
Carén Tailings Deposit
CODELCO Teniente
Tailing Deposit Clear Waters
Basic Engineering
Flow: 1500 L/s Plant
Mo d : 2
Mo t : 3
 0,01
 0,5
4
Effluent treatment plant
Smelt and refinery
CODELCO Ventanas
Acid Plant
Noble Metals Plant
Electrolite WTP
Cooling Waters
Seawage Waters
Design &Construction
Star up
Flow: 30 L/s
As : 2000
F : 100
Se : 400
Cu : 200
Ni : 84
Mo : 0,15
 0,2
 1,0
 0,01
1
2
 0,01
5
Recovered Sea Water Treatment
Plant
Minera
16 Esperanza
Copper concentrate filtrated
water
Design & Construction
Start up
Operation
Flow: 39 L/s
TSS : 1300
TOC : 15
Cu : 0,26
Mo : 0,02
Fe : 1,2
 130
 1
 0,1
 0,1
 0,05
Project:
Project Description:
Punta Chungo
Effluent treatment
facility
This treatment facility was designed and built in 1999 in order to reduce Mo and Cu
concentration, remove ultra fine solids and adjust the pH value of the copper
concentrate filtrate, in order to fulfil the irrigation act.
The processes implemented in this facility were a worldwide unique combination of
dissolved air flotation and ferric co-precipitation technologies for the removal of
dissolved metals.
Client:
Minera Los Pelambres-AMSA
Location:
North of Chile,
Coquimbo Region
The industrial processes were engineered based on laboratory tests and the design
criteria for the industrial facility were defined using a continuous 2 L/s pilot test.
The facility was built in a record time for a 25 L/s average flow.
In 2010, for an upgrade to 42 L/s a details engineering, terrain engineering and
start-up were carried out.
Services delivered:
Phase I (year 1999)
•
Research & development of the treatment technology
•
Pilot plant run
•
Basic and details engineering
•
Equipment & material acquisition
•
Construction & mounting (turnkey)
•
Start-up
•
Operating service
To our best knowledge, first plant
in the world using DAF for
mining effluent treatment
17
Phase II (year 2010)
•
Study and analysis for the expansion project
•
Details engineering
•
Acquisition support
•
Terrain engineering
•
Start-up
Project:
Support for new
regulation compliance
Client:
VOLCAN Compañía Minera
S.A.A.
Location:
Peru
Project Description:
The objective in this project was the definition of the treatment
systems necessary to comply with the new environmental regulations
for the Andaychagua, Mahr Túnel, Carahuacra, Cerro de Pasco and
Animón mining operations.
A water management effluent study was carried out, starting from
basic site information, flows, streams, qualities, and client’s needs.
Processes simulation were conducted by using MatLab – Simulink.
The treatment systems were defined based on laboratory testing of
the current effluents and ARCADIS experience. Furthermore, the
cost, water qualities and flow were estimated for complying with the
new regulation.
Services delivered:
•
•
•
•
18
Effluent quality simulations
Effluent management & optimization
Effluent treatment systems definition
Conceptual & Basic Engineering
Project:
Treatment Plant for
Recovered Sea Water
Client:
Project Description:
The Esperanza project uses sea water for the production of copper concentrate
on the facility located in Sierra Gorda, 150 km from Antofagasta. The concentrate
is sent to the Michilla port for thickening and filtration. Esperanza also uses
desalinated water for washing the concentrate filtrated.
Minera Esperanza
The overflow obtained from the thickening process is treated in the Recovered
Sea Water Treatment Plant, before it is fed to the sea water pipeline that in turns
feeds the Sierra Gorda operation.
Location:
North of Chile,
Antofagasta Region
This facility processes 120 m3/h coming from the overflow of the copper
concentrate thickener, removing 90% of the ultra-fine material. Moreover, it
removes dissolved metals such as copper and molybdenum. The processes used
are ferric co-precipitation and dissolved air flotation for the solid-liquid separation.
AMSA
The treated effluent, i.e. sea water, is introduced in the sea water pipeline feeding
the Sierra Gorda operation, and the flotation sludge is sent to the filtration facility.
Services delivered:
•
•
•
•
19
Details engineering
Construction
Acquisitions
Start-up
Project:
Puerto Patache
Effluent treatment
facility
Client:
Xstrata – Anglo American
Compañía Minera Doña Inés de
Collahuasi
Location:
North of Chile,
Tarapacá Region
20
Project Description:
The Puerto Patache facility processes the concentrate filtration effluent, removing
principally copper and molybdenum. The objective is to produce water of quality
able to comply with the Irrigation Act, regarding elements such as Mo, Cu, Cd,
As. Also, to comply with the Effluent Act regarding the sulphide content. The
elements removed are concentrated in a semi-solid stream that is sent to the
copper concentrate storage.
An air based sulphide oxidation technology was developed for this facility, thus
eliminating the risks of traditional methods.
Services delivered:
•
•
•
•
•
•
Research & development of an air based oxidation technology
Details engineering for the facility
Acquisitions
Construction & assembly (turnkey)
Start-up
Operation service
•
Key
References
•
•
•
•
•
•
•
•
•
21
Alhucema, P., Marinkovic, E., Rubio, J. ”Procesos de remoción de
contaminantes desde efluentes de Plantas Concentradoras”. IV Simposio
Internacional de Mineralurgia - TECSUP, Perú.
Gaete, O., Tiravanti, G., 2012. “Nuevas Tecnologías de Tratamiento de
efluentes mineros: Precipitación de sulfuros y separación con FAD.
Gaete, O., 2012, “Obtaining cooling quality water from an acid plant effluent”.
Water in mining WIM, Santiago, Chile
Frenkel, V., Gaete, O., 2112. “Demand in Water Treatment for Mining
Industry”. III International Seminar on Desalination ALADYR, Antofagasta,
Chile.
Monares, J.T, 2012. “Operación y testeo de planta piloto de desalación de
agua de mar en Singapur mediante sistema de destilación de membrana en
condiciones de vacío”. III International Seminar on Desalination ALADYR,
Antofagasta, Chile.
Alhucema, P., Gaete, O., “Con sulfuro y bario”, Revista Induambiente N°115,
Abril 2012.
P. Alhucema, W. Bustos, E. Marinkovic. Rubio, J. “Al rescate del molibdeno”,
Revista Induambiente N°20.
“Tecnología de exportación”. Revista Induambiente N°47, pág. 105-107.
Rubio, J. Tessele, F. Alhucema, P., Marinkovic, E. “Avances y aplicaciones
en la flotación por aire disuelto”. Revista Minerales_Vol 57, pág. 25-27, 2002.
Gaete, O., Tiravanti, G. “Precipitación con sulfuro y separación sólido líquido
con Flotación por Aire Disuelto FAD”. Revista Tecnología Minera (Perú)
Edición 32- Julio/Agosto 2012 - pág. 112-115.
MWM experience:
Tailings storage facilities
22
TSF designed by ARCADIS (1/2)
It
Mine / Deposit
Owner
Production
KTPD
In
Operation
since (yr)
Final
Capacity
Mton
Dam
height
(m)
Type of tailing
Dam
Material
Country
1
Los Bronces / Las
Tórtolas
AngloAmerican
140
1992
1,000
150
Unthickened
Tailings sand
Chile
2
El Soldado / El Torito
Anglo American
20
1993
82
62
Unthickened
Tailings sand
Chile
3
Salvador / Tranque
Austral
Codelco
33
1990
275
39
Unthickened
Borrow
Chile
4
La Candelaria /
Candelaria
FCX
65
1994
380
180
Thickened
Waste rock
Chile
5
Collahuasi / Pampa
Pabellón
Anglo American,
Xstrata
140
1998
1,780
100
Thickened
Waste rock &
Tailings sand
Chile
6
Andina / Ovejería
Codelco
94
1999
2,100
120
Thickened
Tailings sand
Chile
7
Los Pelambres /
Quillayes
AMSA
130
1999
248
198
Thickened
Tailings sand
Chile
8
Escondida / Laguna
Seca (OGP1)
BHP Billiton
280
1990
4,000
100
Thickened
Borrow
Chile
9
Caserones
Lumina Copper
110
In
construction
2,000
220
Thickened
Slimes
Borrow/ sand
Chile
10 San Vicente
SIMSA
2
1998
1,3
19
Unthickened
Tailings sand
Peru
11 San Rafael / Bodefall III
Minsur
2,2
2001
16
90
Unthickened
Waste rock
Peru
~60-90
2002
475
235
Thickened
Borrow &
Waste rock
Peru
23
12 Antamina
Xstrata/ BHP
TSF designed by ARCADIS (2/2)
It.
Mine / Deposit
Owner
13
Yauricocha / Chinchán
Sociedad Minera
Corona S.A.
14
Casale
Barrick
15
Quellaveco / Cortadera
16
Production
KTPD
In
Operation
since (yr)
Final
Capacity
Mton
Dam
height
(m)
Dam
Material
Country
Unthickened
Tailings Sand
Peru
Type of tailing
1
review
S/I
~100
160
project
1,000
260
Thickened
Borrow/ Sand
Chile
Anglo American
90
Project
1,000
293
Thickened
Tailings Sand
Peru
Potrerillos Plant /
Slag deposit
Codelco
1.3
Project
2
Filtered
No dam
Chile
17
Pelambres/ Mauro
AMSA
175
2008
18
Victoria Plant/ Chumpe
Volcan
8
19
El Peñon /
Meridian
4
20
Mantos Blancos/
Depósito #3
Anglo American
12/17
21
Mantos Blancos/
Depósito #3
Anglo American
12
22
La Colosa
Anglo Ashanti
24
Tailings
transport
1,700
248
Thickened
Tailings Sand
Chile
Project
69
133
High thickened
Borrow
Chile
2000
50
Filtered
No dam
Chile
Project
110
75
High thickened
Waste Rock
Chile
2002
20
50
Filtered &
Thickened
Waste Rock
Chile
Project:
Project Description:
Las Tórtolas Tailing
Impoundment
Client:
Anglo American Chile
Location:
Los Bronces (currently Minera Sur Andes) is located in the San
Francisco Valley. The operation currently processes 152 ktpd of
copper ore. The tailings are deposited at the site of the Las
Tortolas plant. Las Tortolas tailings impoundment was designed
for 1,000 millions tons and it consists of a sand dam of 190 m in
height (at final stage) and has two other smaller dams.
Center of Chile
Services Delivered:
• Design of detailed engineering of the tailings impoundment for
the 55 ktpd flotation plant, including three sand dams, tailings
transport and distribution systems, and water reclaim and
distribution system to the concentrator plant
• Design of conceptual engineering of tailings facilities for 25 and
37 ktpd processing plants
• Design of detail, construction-level engineering of tailings
facilities for 37 ktpd processing plant
• Initial filling of the impoundment
• Support during construction stage
• EPCM New Cycling Stations and Tailings Pipeline
Production:
37-62-152 ktpd
Operation started:
1992
Final Capacity:
> 1,500 Mton
Final Dam Height:
190 m
Dam Material:
25
Tailings sand
Project:
Project Description:
OGP1 - Tailings disposal
and water reclaim
Client:
Minera Escondida – BHP Billiton , Rio
Tinto, JECO Corp, IFC.
Location:
Due to the growth of the pit, Minera Escondida (MEL) has planned
to start the operations of a new concentrator plant called “OGP1
(Organic growth project) Plant”.
In this context, it is necessary to evaluate the impact to the tailings
transport and water reclaim systems with regards to its capacity and
distribution scheme.
North of Chile
Services delivered
•
•
•
•
OGP1 Plant
Production
155 ktpd
Total production
300 ktpd
New concentrator
26
plant operation start
2015
Detailed design of the tailings transport system
Detail Design of the tailings distribution system
Detail Design of the Water Recirculation System.
Construction support
Project Description:
Project:
Laguna Seca Tailing
Impoundment
Client:
Minera Escondida – BHP Billiton
Location:
North of Chile
The Laguna Seca tailings impoundment receives tailings from
the 240 ktpd flotation operation at Minera Escondida. ARCADIS
designed a clear water pond pumping system for the
impoundment. This facility was designed to have clear water,
formed with the water released from the tailings discharged on
the impoundment. The design allowed to isolate barges, in order
to ensure that pumps operate with clear water without solids
content.
Services Delivered:
• Feasibility engineering for water reclaiming system
• Detail engineering for water reclaiming system
Production:
240 ktpd
Operation started:
2001
27
Project:
Project Description:
Quillayes Tailing
Impoundment
Client:
Minera Los Pelambres
Location:
North of Chile
Los Pelambres plant processed by flotation 85 ktpd of copper ore. The
tailings storage facilities include a starter dam 60 m in height and a
sand dam with cycloned sand at 900.000 m3/month. The project
considers a water diversion tunnel of 4,500 m in length. It has a
spillway system that allows for the discharge of more than 300 m3/s.
Water is recovered from the pond by towers.
Services Delivered:
•
•
•
•
•
•
•
Production:
85 ktpd
Operation started / finished:
1999 / 2010
Final Capacity:
360 Mton
Final Dam Height:
198 m
Dam Material:
Tailings sand
28
Study and assessment of alternative sites for the impoundment
Basic studies of hydrology, geology, and geotechnics
Design of basic engineering
Design of detailed engineering
Construction supervision
Commissioning and Start-up
10 years operation of the facilities
Project:
Candelaria Tailing
Impoundment
Client:
Minera Candelaria –
Freeport- McMoRan
Project Description:
The Candelaria tailings impoundment consists of a waste rock
dam, 180 m height. The dam is constructed in 2-4 m layers,
placed directly on the dam by the mine trucks. The
Candelaria tailings operation has the Chilean record in water
recovery, i.e. the lowest make-up water use in the industry.
Services Delivered:
Location:
North of Chile
•
•
•
•
•
•
•
Production:
28 -65 ktpd
Operation started:
1994
Final Capacity:
380 Mton
Dam Height:
180 m
Dam Material:
29
Waste rock
Analysis of alternatives for the impoundment Feasibility
design of the selected alternative
Pre-basic design engineering studies
Geotechnical study of the tailings deposit area
Environmental study
Basic and detailed engineering design for the dam
Support during dam construction
Design of growth of dam to 800 m.a.s.l.
Project:
Ovejería Tailing
Impoundment
Project Description:
Client:
Codelco – División Andina
The Andina Division (CODELCO-Chile) currently processes 94 ktpd
of copper ore, while the initial design was 65 ktpd. The Ovejería
tailings impoundment consists of a tailing sand dam of 4.200 m
length and 120 m height, which results in a tailings storage capacity
of 2.100 Mton.
Location:
Services Delivered:
Center of Chile
•
•
•
•
•
Production:
65 ktpd
Operation started:
1999
Final Capacity:
2.100 Mton
Dam Height:
120 m
Dam Material:
Tailings sand
30
Feasibility studies of various impoundment sites
Seismic risks study
Geological, hydrogeological, and geotechnical studies
Evaluation of borrow pit areas
Characterization of the tailings sand and dynamic analysis of the
sand dam
• Dam design, including starter dam, sand dams, drainage systems,
dam foundation treatment, geotechnical instrumentation
• Design of the water recirculation system and pumps, channels and
electrical power to the systems
• Design of the cyclone plant, electromechanical installations,
positive displacement pumps, sand and slimes piping system
Project:
Pampa Pabellón Tailing
Impoundment
Client:
Cía. Minera Doña Inés de Collahuasi
Xstrata – Anglo American - Mitsui
Project Description:
The project considered a retaining dam, approximately 6 km
length and 90 m of final height. The dam was comprised of
waste rock from the dumps. Water recovery considered towers
and a tailings distribution pipe along the dam crest.
Services delivered:
Location:
• Review and improvement of existing PFS study, optimization
studies
• Water balance for the impoundment
• Dynamic analysis and stability analysis of the dam
• Evaluation of borrow pit areas
• Detail, construction-level engineering design of the tailings
impoundment and associated works
• Design of waste rock retaining dam, water intake tower,
pumping system from the tower, dam seepage system,
seepage water intake structure, seepage pumping system to
booster station, tailings transport and distribution.
• Design of power and instrumentation systems
• Preparation of Bid documentation
• Operation during the first two years
North of Chile
Production:
60 ktpd
Operation started:
1998
Final Capacity:
1.780 Mton
Dam Height:
100 m
Dam Material:
Waste Rock &
Tailings Sand
31
Project Description:
Project:
Chumpe Project
Client:
Volcan Compañía Minera
S.A.A
The basic engineering for the Chumpe deposit from Volcan Mining
Company considered the design of a new dam to handle the tailing
produced from the Victoria plant (Yauli, Perú), which will replace the
current tailing deposit at Rummichaca once its useful life ends.
The scope of the engineering were the dam, surface water
diversion works, tailings transport and distribution, tailings
thickening, water recovery systems, and instrumentation. Trade-Off
studies were conducted to analyze different alternatives for
transportation of tailings and thickening.
Location:
Peru
Services Delivered:
• Trade off studies of tailings transport and thickening options
• Basic engineering of TSF, cycloning and pumping for backfilling
• Onsite geological and geotechnical work, including laboratory
tests to identify the properties of materials.
• Support for environmental studies and formalities required for the
management and disposal of tailings.
Production:
8 ktpd
Operation to be started
2017?
Final Capacity:
69 Mt
Final Dam Height:
133 m
Dam Material:
Borrow
32
Project:
La Colosa Project
Client:
Anglo Gold Ashanti
Location:
Tolima district, Colombia
Project Description:
La Colosa porphyry gold project is located 150km west of Colombia’s
capital city, Bogota. The area is characterized by having steep valleys
and forest reserve.
Trade offs studies were developed to analyze different tailings/ ore
transport system options:
• 105 km of ore duct (4 choke station + 6 water pump station)
• Belt conveyor (30 km) + tailings duct (35 km)
Services Delivered:
Trade-Off Study:
• Plant Location/ Ore Transportation/ Tailings Transportation
Mine Facilities:
• Buildings/ Truck shop/ Roads/ Camps
33
•
•
Key
References
•
•
•
•
•
•
•
•
34
Valenzuela, L. y Barrera, S.,1995, "Grandes Presas de Relaves: Práctica Actual
en Chile", X Congreso Panamericano de Mecánica de Suelos e Ingeniería de
Fundación, Guadalajara, Méjico
Barrera, S. 2010. Deposition densities of tailings in Chilean deposits, Tailings
and Mine Waste ‘98, Colorado, USA
Valenzuela, L. y Barrera S., 2000, “Environmental, Operational and Economical
Balance in the Design of a Tailings Impoundment”, GeoEng2000 - An
International Conference on Geotechnical & Geological Engineering, Nov.‘00,
Melbourne, Australia
Pinto, M and Barrera, S., 2002, “Tailings Beach Slope Forecasting”, Tailings and
Mine Waste ‘02 Conference, Fort Collins, Colorado, EEUU
Alarcón, J.C. and Barrera, S., 2003, “Dams of Great Height, a Challenge”,
Symposium on Major Challenges in Tailings Dams, CIGB-ICOLD, June,
Montreal, Canada
Barrera, S. y Campaña, J., (2004), “Análisis de Estabilidad de Presas de
Relaves - Práctica Chilena”, 5º Congreso Chileno de Ingeniería Geotécnica,
Santiago
Pinto, M. & Barrera, S., 2008, “Tailings Impoundments – Water Balance –
Methodology”. WIM2008. I International Congress on the Water Management in
the Mining Industry”, July, Santiago, Chile
Riveros, C. and Barrera, S. 2009. “Caserones: Option of Tailings Classifying to
Improve Water Reclamation”. 12th International Seminar on Paste & Thickened
Tailings, May, Viña del Mar, Chile
Barrera, S., Valenzuela, L. and Campaña, J., 2011, “Sand Tailings Dams:
Design, Construction and Operation”, Tailings and Mine Waste 2011
Conference, Nov. 06 -09, Vancouver, Canada
Ortiz, J, Urquidi, J, Pollak, D and Barrera, S, 2012, “Downstream to Centerline
Construction: The Challenge of Change”, Tailings and Mine Waste 2012
Conference, Oct. 16 – 18, Keystone, Colorado
MWM experience:
Waste rock deposits
35
Project:
Project Description:
Design of a 2,800 Mton,
High-Mountain Waste
Rock Dump
The expansion of Andina Division (CODELCO-Chile) involves the construction of
a 2,800 Mton waste rock deposit, which has a maximum front height of 990 m and
rock thickness up to 550 m. The deposit is located at 3,000-3,600 m.a.s.l., within
a narrow, high-mountain valley, in an area of high seismicity.
Client:
CODELCO - División Andina
Location:
Center of Chile
ARCADIS designed the waste rock deposit and the water diversion system. The
design criteria considered structure stability, environmental sustainability, and
cost effectiveness. The design was consistent with different growth rates of the
deposit, as required by the expansion project. Also, the design minimized rehandling of waste rock for the closure condition.
Services Delivered:
•
•
•
•
•
•
•
36
Geotechnical characterization of materials under high pressures (laboratory
testing with large cells, H = 1.8 m)
Design and modulation of the deposit consistent with the current and future
mining operation and with the existing infrastructure
Design of the water diversion system
Design of the basal drain system
2D and 3D stability analysis
Formal dynamics analysis of stability
Operating Manuals (construction
consideration of climate conditions)
recommendations
and
restrictions,
Project:
Master Plan for San
Francisco 2,400 Mton
Low Grade Ore and
Waste Rock Dump
Client:
Minera Sur Andes- Anglo
American
Project Description:
The mining operation at Minera Sur Andes required preparation of a Master Plan
to construct and to operate the San Francisco waste rock and low grade ore
deposit. The deposit is designed for a capacity of 2,400 Mton and is located at
3,200 m.a.s.l. (average), within a glacial valley in an area of high seismicity.
ARCADIS prepared the Master Plan. The design took under consideration that the
low grade ore is deposited on separated areas within the San Francisco deposit
and subjected to leaching for copper recovery.
Services Delivered:
• Geological and hydrogeological characterization of materials
Location:
Center of Chile
• Geotechnical characterization of waste rock and foundation materials under
high pressures (laboratory testing with large cells, H = 1.8 m)
• Design of the high mountain water collection and diversion system
• Design of methods for waste depositation on high slope areas
• Design of a high mountain pond for storage and treatment of ARD solutions
• Static and dynamic stability analysis (operation and closure)
• Handling methods for loading waste rock on organic soils
• Recommendations for the treatment of deposit foundations
• Geological risks analysis and feasibility analysis
• Avalanche risks analysis
• Construction recommendations and restrictions
37
Project:
ARD Handling in a HighMountain Waste Rock
Dump
Client:
CODELCO - División Andina
Location:
Center of Chile
Project Description:
The expansion of Andina Division (CODELCO-Chile) involves the construction
of a 2,800 Mton waste rock deposit, located at 3,000-3,600 m.a.s.l., within a
narrow, high-mountain valley, in an area of high seismicity.
ARCADIS designed the environmental solution required for handling and
control of acid rock drainage (ARD) from the waste rock, key aspect which
gives sustainability to the Expansion project (currently 92 ktpd of ore, 230 ktpd
of ore in the future). The ARD solution developed considered geochemical
modeling and engineering design of prevention and treatment works.
Services Delivered:
• Dynamic modeling of solution and contaminants balance in the waste rock
dump and within the complete solution circuit, down to the control point. The
model was used to assess the design criteria and the correct interaction
among the different constituents of the environmental solution
• Design of interception works for large amounts of clear water, for both
concentrated streams and for diffuse streams, in high slope areas
• Design of conduction and discharge works for deviated water
• Design of collection and conduction systems for ARD solutions generated
by the waste rock dump
• Design of all engineering works for the complete solution circuit, including a
retaining pond, a seepage control wall, a solution treatment plant
(neutralization, HDS technology), and pumping systems for treated water
and removal of sludge
38
Project:
Project Description:
Design of Waste Rock
Dumps Founded on
Weak Foundation
Soils
In some cases, waste rock deposits must be located on weak foundations, i.e.
on rock glaciers in high-mountain settings, on organic soils, and on tailings.
Local deformations induced by such weak foundations could promote a sliding
triggering mechanism for major failures in waste rock dumps, and rock flows
could occur.
ARCADIS has devised and proposed recommendations for design and
operation. Weak foundations should be avoided, removing the weak material.
Also, dedicated sequences for growth of the deposit should be used,
encapsulating the weak material area. Foundation treatment is another
alternative although not always a practical approach. Special attention should be
given to permafrost conditions associated with the melting of ice, due to the high
stresses imposed by the dump.
Services delivered:
S6
S8
S7
ROCA
S4
S5
39
S1
S2
S3
•
•
•
•
Geological and geotechnical studies of the foundation soils
Stability and creep analysis validated by topography monitoring
Recommendations for treatment of the foundation soils
Planning of waste loading on rock glaciers and displacement monitoring
Key
References
• Cabezas, R., Sáez, E., y Bard, E.: Modelación Numérica del Comportamiento
Mecánico de Lastres Mineros. VII Congreso Nacional de Geotecnia, Concepción,
28-30 Noviembre. 2012, Chile.
• Valenzuela, L.; Bard, E.; Campaña, José. (2011): Seismic Considerations in the
Design of High Waste Rock Dumps, 5th International Conference on Earthquake
Geotechnical Engineering, 10 – 13 January, Santiago de Chile.
• Bard, E.; Anabalón, MªE. (2010): Comportement de Stériles à Hautes Pressions –
Applications au Dimensionnement de Dépôts de Grande Hauteur. Chapitre 4,
Livre d´hommage au Professeur Jean Biarez : « Du Sol à l’Ouvrage : une vision
multi-échelles de la Geomécanique », Lavoisier, Paris, Francia, 2010.
• Pollak, D.; Bard, E.: (2009): Consideraciones para Diseño Dren Basal de
Depósitos de Lastre de Gran Altura, Congreso Sudamericano de Geotécnicos
Jóvenes, Córdova, Argentina.
• Bard, E.; Anabalón, MªE. and Campaña; J.: Waste Rock Behavior at High
Pressures: Dimensioning High Waste Rock Dumps, Chapter 4 in “Multiscale
Geomechanics from Soil to Engineering Projects”, John Wiley & Sons, Inc., USA,
October 2011.
• Bard, E.; Anabalón, MªE. (2008): Comportement de stériles à hautes pressions;
Journée d´hommage au Professeur Jean Biarez, Comité Français de Mécanique
des Sols et de Géotechnique, 12 mars.
• Valenzuela, L.; Bard, E.; Campaña J.; Anabalón, MªE. (2008): High Waste Rock
Dumps- Challenges and Developments, 1st International Seminar on the
Management of Rock Dumps, Stockpiles and Heap Leach Pads, pp. 65 - 78, 5 - 7
March 2008, Perth, Western Australia.
• Bard, E.; Anabalón, Mª E.; Campaña, J.; Apablaza, R.; Gallardo, M.; (2007):
Comportamiento de Lastre ROM sometido a Altas Presiones, VI Congreso
Chileno de Geotecnia, Valparaíso, 28 al 30 de Noviembre 2007.
• Bard, E.; Campaña, J.; Anabalón MªE.; Apablaza, R., (2007): Waste Rock
Behavior at High Pressures, XIII Pan- American Conference on Soil Mechanics
and Geotechnical Engineering, paper 254, Margarita, Venezuela, Julio 2007.
40
MWM experience:
Leaching tails
41
Project:
Heap Leach Pads and
Dump Leach Basal
Drainage Systems
Client:
Minera Spence – BHP Billiton
Location:
North of Chile
Project Description:
The Spence operation was designed to process 50 kt/d of mixed and sulphide
copper ore, to produce 200 kt per year of copper cathodes. The mine
commenced production in mid-2006. The Spence project was planned in three
phases, involving the sequential construction of sections of the leaching pads in
each phase.
ARCADIS has been involved in the project since 2007, providing a range of
services related to on-off heap leach pads and dump leaching, from specialized
geotechnical engineering to on-site construction support, trade-off analysis, and
multidisciplinary engineering and cost estimates.
Services Delivered:
• Evaluation and optimization of the drainage system of mixed and sulphide
leach pads constructed in Phase I of the project
• Geotechnical studies
• Definition, programming, supervision and analysis of in-situ and laboratory
tests
• Development of trade-off studies
• Introduction of an innovative solution to improve the bearing capacity of the
cover in both pads
• Selection and definition engineering
• Detail engineering of the drainage system design for Phases II and III
• Cost estimations
• On-site geotechnical and construction support
• Provide advice for hydrodynamic characterization of the mixed and sulphide
ores leached in the pads as basic background to support design of the
aeration system
42
Project:
Secondary Leach of
Heap Leach Tails
Client:
CODELCO - Radomiro Tomic
Location:
North of Chile
Project Description:
Radomiro Tomic (Codelco-Chile) runs a heap leach operation of crushed high
grade copper ore, a ROM dump leach operation for low grade oxides, and a
process of secondary leaching of the heap leaching tails in a static heap, to
produce a total of 300 kt per year of copper cathodes.
ARCADIS has been involved from the beginning of the secondary leach project.
Studies were associated to the sequential expansion phases of the tailings
deposit, which was designed for 600 Mton of tails reaching a final height of 110
m and covering an area of 5,5 Mm2. Later, studies were conducted by ARCADIS
to increase capacity by additional 344 Mton of tails.
Services Delivered:
• Selection of the base geomembrane as a function of the deposit height (large
scale cut tests)
• Testing and assessment of drainage piping under high loading due to deposit
height
• Design of the drainage and solution collection systems as a function of deposit
height
• Design of a cost-effective mixed cover for the solution basal drainage system
• Static, pseudo-static, and dynamic stability analysis
• Support to an industrial scale test of tails leaching
• Provide stability restrictions to leaching
• For expansion, preparation of the deposit foundation, design of earth works for
platforms, design of on-heap road for transport of the spreader.
• For expansion, stability analysis, design of drainage and collection systems,
design of de-sanders and solutions ponds
• Design of geotechnical monitoring system (phreatic level and drainage pipes)
43
Project:
Secondary Leaching
of Heap Leaching
Tails
Client:
CODELCO - Minera Gaby
Location:
North of Chile
Project Description:
Minera Gaby (Codelco-Chile) processes crushed high grade copper ore in a onoff heap leach operation. Currently the leaching tails are subjected to secondary
leaching in the tailing deposit, to produce a total 140 kt per year of copper
cathodes.
ARCADIS has conducted studies related to both the design of the tails deposit
and the leaching process, including geotechnical characterization of tail samples
to estimate material parameters and to assess stability as a function of loading
methodology and leaching conditions. The engineering design was aimed to
optimize the drainage system and solve interferences with the existing system.
Stability analysis were conducted under different secondary leaching scenarios
to assess feasibility. Solution and mass balance simulations were run under
different processing scenarios to establish copper production, acid consumption,
and water consumption.
Services delivered:
•
•
•
•
•
•
•
•
•
•
•
44
Geological and geotechnical studies
Hydrodynamic and geotechnical characterization of leaching tails
Conceptual engineering design of the secondary leaching project
2D finite elements and 3D stability analysis
Design of the basal drainage system
Dynamic modeling of solution and mass balance, integrating geotechnical and
process requirements and restrictions
Determination of project requirements in following phases
Early works basic engineering design
Construction support
Technical recommendations for the leaching operation
Design of monitoring programs and action plans
Project:
Gold Recovery
Increase at Alhué
Plant
Client:
Minera Florida - YAMANA
Location:
Metropolitan Region
Project Description:
Minera Florida (Yamana Gold) processes gold minerals at 70,000 tpm at the Alhué
plant. The process involves the stages of grinding and bulk flotation of Au-Zn,
agitated cyanide leaching of Au-Zn concentrate, Zn flotation from leach tailings to
obtain Zn concentrate, and PLS electrowinning to obtain doré.
ARCADIS developed the Tailings Processing Plant project (PTR project) aimed to
reprocess 100,000 tpm of Au tailings for metal recovery. The PTR metallurgical
process designed was complex and involved hydraulic extraction of tailings from
the dams and transport to the PTR plant, classification of re-pulped tailings,
grinding and classification in direct closed-circuit, cyanide agitated leaching, Au and
Ag recovery in a modern CIP process, elution and regeneration of activated
carbon, Au-Ag recovery by EW, detoxification of cyanidation tailings, filtering and
washing of tailings, detoxification of filtered solutions, flotation of washed tailings for
Zn recovery, and loading the final tailings in the current tailing dam.
Services delivered:
•
•
•
•
•
45
Metallurgical characterization of tailings and leaching testing
Detail engineering of the PTR plant, 3D
Innovative design of the ADR circuit by incorporation of a carrousel C system
Operational Manuals and training
Construction support
•
Key
References
•
•
•
•
•
•
•
46
León, R., Bard, E. Campaña, J., Lagos, M.: Análisis de Tuberías
Enterradas – Depósitos de Gran Altura. VII Congreso Nacional de
Geotecnia, Concepción, 28-30 Noviembre. 2012, Chile.
Campaña, J.; Bard, E.; Anabalón, MªE.; León, R., (2007): Geotechnical
characteristics of primary and secondary leach copper ore, XIII Pan American Conference on Soil Mechanics and Geotechnical Engineering,
paper 454, Margarita, Venezuela, Julio 2007.
Bard E., Campaña J., (2004): Aspectos Geotécnicos en el Diseño de Pilas
y Botaderos de Ripios Lixiviados. V Congreso Chileno de Ingeniería
Geotécnica, Noviembre 2004.
Bard E., Campaña J., Garrido H. (2003): Caracterización Interfaz de
Material Granular y Geomembrana. 12ava Conferencia Panamericana de
Mecánica de Suelos e Ingeniería Geotécnica. Cambridge USA, June 22 –
26.
Andrade C., Bard O., Garrido H., Campaña J.(2000): Radomiro Tomic
Secondary Heap Leach Facility, in Slope Stability in Surface Mining,
Chapter 48, pp. 427-434. Edited by the Society of Mining, Metallurgy and
Exploration, Inc. (SME).
Bard E., Campaña J., Garrido, H. (2000): Depósitos de Ripios Lixiviados –
Caracterización interfaz de material granular y geomembrana. 3er
Congreso de Minería del Perú. Huaraz-Perú.
Campaña, J., Andrade, C., Bard, E. (1999): Parámetros de Resistencia al
Corte en un Depósito de Lastre Mineral. XI Congreso Panamericano de
Mecánica de Suelos e Ingeniería de Fundaciones, Iguazú, Brasil.
Andrade, C., Bard, E., Campaña, J., Paredes, L. (1997): Caracterización
Geotécnica de Interfaces de Materiales Granulares y Geomembranas, 4º
Congreso Chileno de Ingeniería Geotécnica, Valparaíso, Chile, Vol. I, pp
437-454.
Mining Clients
47
Top Mining clients
48
Imagine the result
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